Warp knitted fabric and manufacturing method thereof

ABSTRACT

A warp knitted fabric formed of yarns fed from at least three guide bars including front, middle, and back guide bars, in which a back yarn 3 fed from the back guide bar forms a cord knit texture, a front yarn 1 fed from the front guide bar and a middle yarn 2 fed from the middle guide bar are arranged alternately in a weft direction, each of the front yarn 1 and the middle yarn 2 forms a stitch formation texture (a denbigh knit texture or a cord knit texture) and an insertion texture alternately in a warp direction, and the insertion texture 20 formed by the front yarn 1 and the insertion texture 21 formed by the middle yarn 2 are arranged alternately at least in the warp direction so that the front yarn 1 and the middle yarn 2 are exposed alternately at least in the warp direction on sinker loops of the back yarn 3.

TECHNICAL FIELD

The present invention relates to a warp knitted fabric having a wovenfabric appearance, and a manufacturing method thereof.

BACKGROUND ART

Traditionally, in various fields of related art, there has been a demandfor a knitted fabric having a woven fabric appearance, to be used for anapplication requiring a stretch characteristic, for example, clothing,interior materials, vehicle interior materials, etc. The knitted fabrichaving the woven fabric appearance may be, for example, a warp knittedfabric in which warps are inserted, a warp knitted fabric in which weftsare inserted, etc. However, there has been a problem in that the stretchcharacteristic is suppressed due to an insertion yarn by which the warpknitted fabric has the woven fabric appearance.

In order to solve the problem, Patent Document 1 describes that a warpknitted fabric is knitted by two or more guide bars by feeding asynthetic-fiber filament yarn A of a total 50 to 100 denier from one ofa front guide bar and a back guide bar, and feeding a synthetic-fiberfilament yarn B with a total denier of 40 to 60% of the synthetic-fiberfilament yarn A from the other, and is subjected to a wrinkleprocessing. With this configuration, the warp knitted fabric of PatentDocument 1 has an excellent stretchability while having the woven fabricappearance. However, since the warp knitted fabric of Patent Document 1merely expresses the wefts of the fabric by floating sinker loops of thefront yarn by performing the wrinkle processing on the tricot knittedfabric knitted by the two guide bars, the woven fabric appearance isinsufficient, and the stretch characteristic is also insufficient.Further, since the tricot knitted fabric is knitted by the two guidebars, there is a problem in that, especially, the tear strength isdegraded.

PRIOR ART DOCUMENT Patent Document

Patent Document 1: Japanese Patent Laid-Open Publication No. 08-269851

DISCLOSURE OF THE INVENTION Problem that the Invention is to Solve

The present invention provides a warp knitted fabric of which physicalproperty needed for an application requiring the stretch characteristic,especially, tear strength is excellent while having a woven fabricappearance, and a manufacturing method thereof.

Means for Solving the Problem

The present invention provides a warp knitted fabric formed of yarns fedfrom at least three guide bars including front, middle, and back guidebars, in which a back yarn fed from the back guide bar forms a cord knittexture, a front yarn fed from the front guide bar and a middle yarn fedfrom the middle guide bar are arranged alternately in a weft direction,each of the front yarn and the middle yarn forms a stitch formationtexture and an insertion texture alternately in a warp direction, thestitch formation texture of each of the front yarn and the middle yarnis a denbigh knit texture or a cord knit texture, and the insertiontexture formed by the front yarn and the insertion texture formed by themiddle yarn are arranged alternately at least in the warp direction sothat the front yarn and the middle yarn are exposed alternately at leastin the warp direction on sinker loops of the back yarn.

In this warp knitted fabric, it is preferable that the front yarn fedfrom the front guide bar and the middle yarn fed from the middle guidebar are arranged alternately in the weft direction. Further, it ispreferable that each of the front yarn and the middle yarn forms thedenbigh knit texture and the insertion texture alternately in the warpdirection (i.e., it is preferable that the stitch formation texture isthe denbigh knit texture).

In addition, in this warp knitted fabric, a ratio of the insertiontexture exposed on a surface of the warp knitted fabric is preferably 15to 60%.

In addition, the present invention provides a method of manufacturingthe warp knitted fabric, using a warp knitting machine provided with atleast three guide bars including front, middle, and back guide bars,knitting a cord knit texture by feeding a back yarn from the back guidebar, knitting a stitch formation texture and an insertion texturealternately in a warp direction by feeding a front yarn from the frontguide bar, knitting a stitch formation texture and an insertion texturealternately in the warp direction by feeding a middle yarn from themiddle guide bar, knitting a denbigh knit texture or a cord knit textureas the stitch formation texture of each of the front yarn and the middleyarn, and arranging the insertion texture formed by the front yarn andthe insertion texture formed by the middle yarn alternately at least inthe warp direction so as to expose the front yarn and the middle yarnalternately at least in the warp direction on sinker loops of the backyarn.

Advantage of the Invention

According to the warp knitted fabric and the manufacturing methodthereof in the present invention, the insertion textures by the frontyarn and the middle yarn are exposed alternately at least in the warpdirection on the sinker loops of the back yarn, so that the design ofthe woven fabric may be provided. That is, the front yarn and the middleyarn in the insertion textures are exposed on the sinker loops formed bythe back yarn so as to cover and hide the sinker loops, and as a result,the design of the woven fabric may be provided.

Further, the sinker loops of the back yarn fed from the back guide barare pressed by the stitch formation textures (i.e., the denbigh knittextures or the cord knit textures) and the insertion textures formed bythe front yarn and the middle yarn, so that the warp knitted fabric ofwhich physical property needed for the application requiring the stretchcharacteristic, especially, tear strength is excellent may be provided.

Further, the stitch formation texture (i.e., the denbigh knit texture orthe cord knit texture) and the insertion texture by each of the frontyarn and the back yarn are formed alternately, so that the stretch inthe warp direction is suppressed, and thus, the warp knitted fabrichaving an excellent stretch balance in the warp and weft directions maybe provided.

Thus, according to the present invention, it is possible to provide awarp knitted fabric of which physical property needed for theapplication requiring the stretch characteristic, especially, tearstrength is excellent while having the woven fabric appearance, and amanufacturing method thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view illustrating a main portion of a warpknitting machine used for knitting a warp knitted fabric according to anembodiment.

FIGS. 2A to 2C are examples of a texture view of the warp knitted fabricaccording to the embodiment, in which FIG. 2A illustrates a case where afront yarn 1 and a middle yarn 2 are fed 1 in 1 out such that a denbighknit texture and an insertion texture are formed alternately, FIG. 2Billustrates a case where the front yarn 1 and the middle yarn 2 are fed2 in 2 out such that the denbigh knit texture and the insertion textureare formed alternately, and FIG. 2C illustrates a case where the frontyarn 1 and the middle yarn 2 are fed 1 in 3 out such that the denbighknit texture and the insertion texture are formed alternately.

FIG. 3 is a schematic perspective view of an example of the warp knittedfabric according to the embodiment.

FIGS. 4A and 4B are schematic enlarged cross-sectional views explaininga portion of the warp knitted fabric according to the embodiment, inwhich FIG. 4A illustrates a state where the front yarn 1 (or the middleyarn 2) is in contact with the back yarn 3, and FIG. 4B illustrates astate where the front yarn 1 (or the middle yarn 2) floats from the backyarn 3.

FIG. 5 is a texture view of Examples 1 and 6.

FIG. 6 is a texture view of Example 2.

FIG. 7 is a texture view of Example 3.

FIG. 8 is a texture view of Example 4.

FIG. 9 is a texture view of Example 5.

FIG. 10 is a texture view of Example 7.

FIG. 11 is a texture view of Example 8.

FIG. 12 is a texture view of Comparative Example 1.

FIG. 13 is a texture view of Comparative Example 2.

BEST MODE FOR CARRYING OUT THE INVENTION

The present embodiment provides a warp knitted fabric formed of yarnsfed from at least three guide bars including front, middle, and backguide bars, in which a back yarn fed from the back guide bar forms acord knit texture, a front yarn fed from the front guide bar and amiddle yarn fed from the middle guide bar are arranged alternately in aweft direction, each of the front yarn and the middle yarn forms astitch formation texture and an insertion texture alternately in a warpdirection, the stitch formation texture of each of the front yarn andthe middle yarn is a denbigh knit texture or a cord knit texture, andthe insertion texture formed by the front yarn and the insertion textureformed by the middle yarn are arranged alternately at least in the warpdirection so that the front yarn and the middle yarn are exposedalternately at least in the warp direction.

The warp knitted fabric of the present embodiment may be a tricotknitted fabric, a single Raschel knitted fabric or the like.

The warp knitted fabric of the present embodiment is knitted by a 16- to40-gauge warp knitting machine provided with at least three guide bars,for example, one front guide bar GB1, one middle guide bar GB2, and oneback guide bar GB3 as schematically illustrated in FIG. 1. Especially,an 18- to 36-gauge warp knitting machine is preferable. When the numberof gauges is 16 or more, a loop in a width direction is small, and thus,it is difficult for the insertion texture to float, so that theanti-pilling property is hardly damaged. When the number of gauges is 40or less, the stretch of the knitted fabric is large, so that wrinklesare hardly formed. The warp knitting machine described above may be atricot knitting machine, a Raschel knitting machine or the like.

FIG. 1 illustrates a main portion of a tricot knitting machine that is akind of the warp knitting machine, in which N indicates multipleknitting needles arranged in parallel in the width direction of theknitting machine, GB1 to GB3 indicate the respective guide bars used forknitting, G1 to G3 indicate guide portions through which the knittingyearns including the front yarn, the middle yarn, and the back yarn arethreaded, and B1 to B3 indicate beams of the respective knitting yarns.Further, in the drawing, the reference numeral 1 indicates the frontyarn, the reference numeral 2 indicates the middle yarn, and thereference numeral 3 indicates the back yarn.

In the present embodiment, the fiber used as the front and middle yarnsis not particularly limited. A polyester fiber is preferable in view ofa physical property.

A form of the yarns used for the front and middle yarns is not alsoparticularly limited. Any of spun yarns and filament yarns may be used.In addition, as the filament yarns, any of monofilament yarns andmultifilament yarns may be used. In addition, processed yarns which areobtained by post-processing the filament yarns may be used. The form ofthe yarns may be appropriately set according to an application. Inaddition, when a yarn with a functional property (e.g., awater-absorptive yarn) is used, the functional property may be provided,and when a yarn having a high design property (e.g., a lame or chenilleyarn) is used, the design property may be provided.

A fineness of the yarns used for the front and middle yarns ispreferably 56 to 330 dtex, and more preferably 84 to 220 dtex. When thefineness of the yarns is 56 dtex or higher, the design of the wovenfabric by the insertion texture is hardly damaged, and further, thestrength is hardly damaged. When the fineness of the yarns is 330 dtexor lower, the feeling of the knitted fabric hardly becomes rough andhard, and further, the anti-snagging property is hardly damaged.

The fiber used as the back yarn is not particularly limited. A polyesterfiber is preferable in view of a physical property.

The form of the yarn used for the back yarn is not also particularlylimited. Any of a spun yarn and a filament yarn may be used. Inaddition, as the filament yarn, any of a monofilament yarn and amultifilament yarn may be used. In addition, a processed yarn which isobtained by post-processing the filament yarn may be used. The form ofthe yarn may be appropriately set according to an application.

The fineness of the yarn used for the back yarn is preferably 56 to 440dtex, and more preferably 84 to 220 dtex. When the fineness of the yarnis 56 dtex or higher, the swelling of the sinker loops is sufficient sothat the knitted fabric hardly becomes see-through, and further, thestrength is hardly damaged. When the fineness of the yarn is 440 dtex orless, the feeling of the knitted fabric hardly becomes rough and hard,and the stretch characteristic is hardly deteriorated.

In the knitting of the warp knitted fabric of the present embodiment,for example, when the knitting is performed by the tricot knittingmachine provided with the three bars GB1 to GB3, the so-called backguide bar GB3 on the rear side of the knitting machine (the side wherethe position of the guide bar becomes closest to the row of the knittingneedles at the time of underlapping) is used as a base guide bar thatfeeds the back yarn. The back guide bar GB3 knits the cord knit texturein which the back yarn forms stitches (looping) while underlapping tothe left and the right alternately in each course.

Further, at least two guide bars arranged in front of the back guide barGB3, for example, the front guide bar GB1 and the middle guide bar GB2are used as guide bars that feed the front yarn and the middle yarn.Each of the front guide bar GB1 and the middle guide bar GB2 knits thestitch formation texture, in which each yarn forms stitches whileunderlapping to the left and the right alternately in each course, andthe insertion texture alternately in the warp direction. Here, thestitch formation texture of each of the front yarn and the middle yarnis the denbigh knit texture or the cord knit texture. Accordingly, eachof the front guide bar GB1 and the middle guide bar GB2 knits thedenbigh knit texture and the insertion texture alternately in the warpdirection or the cord knit texture and the insertion texture alternatelyin the warp direction.

As a result, on the sinker loops of the back yarn, the insertiontextures of the front yarn and the middle yarn are knitted across thesinker loops of the back yarn at predetermined intervals in the coursedirection (warp direction), so that the design of the woven fabric isprovided. Further, the stitch formation textures of the front yarn andthe middle yarn (i.e., the denbigh knit textures or the cord knittextures) are knitted as base textures together with the back yarn, sothat the strength is improved.

In the case of the present embodiment, in the knitting described above,the front yarn fed by the front guide bar GB1 and the middle yarn fed bythe middle guide bar GB2 are arranged alternately in the weft direction.Specifically, in the two guide bars including the front guide bar GB1and the middle guide bar GB2, a row set for yarn-in of the front yarn isalso set for yarn-out of the middle yarn, and a row set for yarn-in ofthe middle yarn is also set for yarn-out of the front yarn, such that itis important that yarn-in of the front yarn and yarn-in of the middleyarn are not performed in the same row. There may be a row set for bothyarn-out of the front yarn and yarn-out of the middle yarn.

In addition, the terms “the front yarn and the middle yarn are arrangedalternately in the weft direction” mean not only that one front yarn andone middle yarn are arranged alternately in the weft direction, but alsothat one or multiple front yarns continuously arranged in the weftdirection and one or multiple middle yarns continuously arranged in theweft direction are arranged alternately in the weft direction.Accordingly, for example, two front yarns continuously arranged in theweft direction and two middle yarns continuously arranged in the weftdirection may be arranged alternately in the weft direction.

In addition, when each of the front yarn and the middle yarn forms thecord knit texture and the insertion texture alternately, it is importantthat yarn-out is performed, for example, in a X− in (X+α)-out pattern (αis 0 or a natural number), to suppress the insertion texture of one sidefrom being pressed by the cord knit texture of the other side. That is,it is important that 1 or more yarn-out is performed for 1 yarn-in. Forexample, it is important that when 3 yarn-in is performed, 3 or moreyarn-out is performed such that 3 in 3 out, 3 in 4 out, or 3 in 5 out,etc. is performed. Here, a is preferably an even number, and morepreferably 0 or 2. When a is an even number, the insertion textures arehardly biased to the left or right, so that the appearance of the wovenfabric becomes satisfactory. Further, when a is 2 or lower, a sufficientnumber of the insertion yarns across the sinker loops of the back yarnare secured, so that the appearance of the woven fabric becomessatisfactory.

Since the front yarn fed by the front guide bar GB1 and the middle yarnfed by the middle guide bar GB2 are arranged alternately in the weftdirection, the front yarn and the middle yarn are arranged alternatelyin the width direction (the weft direction) in the obtained warp knittedfabric.

In addition, the front yarn fed from the front guide bar GB1 knits astitch formation texture (i.e., the denbigh knit texture or the cordknit texture) A and an insertion texture B alternately in the warpdirection. Further, as well-known, the denbigh knit texture or the cordknit texture is a knit texture in which each yarn forms stitches whileunderlapping to the left and the right alternately in each course,across several courses in the knitting direction. Similarly, the middleyarn fed from by the middle guide bar GB2 also knits a stitch formationtexture A′ and an insertion texture B′ alternately in the warpdirection. It is important that the insertion texture B formed by thefront yarn and the insertion texture B′ formed by the middle yarn arearranged alternately in the course direction (the warp direction). Bythis arrangement and the above-described arrangement (i.e., thealternate arrangement of the front yarn and the middle yarn in the weftdirection), the portions of the insertion texture B of the front yarnand the insertion texture B′ of the middle yarn are not pressed by theopposing portions of the denbigh knit texture or the cord knit texture Aand the denbigh knit texture or the cord knit texture A′, and areexposed alternately on the surface of the warp knitted fabric, so thatespecially, the satisfactory appearance of the woven fabric may beobtained.

In the stitch formation textures (i.e., the denbigh knit textures or thecord knit textures) formed by the front yarn and the middle yarn, it isimportant that the number of underlaps is 1 or more needles, andpreferably, 1 to 3 needles. When the number of underlaps is 1 or moreneedles, the tear strength or the stretch characteristic is hardlydamaged. In addition, a case where “the number of underlaps is less thanone needle” corresponds to a case where knitting is made with the sameknitting needle in the course direction, that is, a chain stitch textureis knitted. In addition, when the number of underlaps is 3 or lessneedles, the design of the woven fabric is hardly damaged, and thefeeling of the knitted fabric hardly becomes rough and hard. Inaddition, it is preferable that the number of underlaps in the stitchformation textures (i.e., the denbigh knit textures or the cord knittextures) formed by the front yarn and the middle yarn is the same, fromthe viewpoint that the front yarn and the middle yarn mutually exposethe insertion textures.

It is important that the number of courses in which the stitch formationtexture (i.e., the denbigh knit texture or the cord knit texture) andthe insertion texture formed by each of the front yarn and the middleyarn are continuously knitted is 1 or more, preferably 1 to 5, and morepreferably 1 to 3. When the number of continuously knitted courses is 5or less, the anti-snagging property is hardly deteriorated.

FIGS. 2A to 2C illustrate examples of texture views of the warp knittedfabric which is knitted as described above. In FIGS. 2A to 2C, the backyarn 3 is drawn in a dashed line, and the front yarn 1 and the middleyarn 2 are drawn in solid lines. In the knit textures of FIGS. 2A to 2C,the back yarn 3 is fed in a full set to form the cord knit texture. Inaddition, in the knit texture of FIG. 2A, the front yarn 1 and themiddle yarn 2 are fed 1 in 1 out to form the denbigh knit texture andthe insertion texture alternately. In addition, in the knit texture ofFIG. 2B, the front yarn 1 and the middle yarn 2 are fed 2 in 2 out toform the denbigh knit texture and the insertion texture alternately. Inaddition, in the knit texture of FIG. 2C, the front yarn 1 and themiddle yarn 2 are fed 1 in 3 out to form the denbigh knit texture andthe insertion texture alternately.

As a result of the knitting described above, a portion 20 of theinsertion texture of the front yarn 1 and a portion 21 of the insertiontexture of the middle yarn 2 are exposed on the surface of the warpknitted fabric as illustrated in FIGS. 2A to 2C and 3. Since theportions 20 and 21 of the insertion textures are periodically arrangedat intervals in the warp direction and the weft direction, the warpknitted fabric exhibits the especially satisfactory appearance of thewoven fabric.

It is preferable that an overlap of a needle loop in the denbigh knittexture or the cord knit texture A formed by the front yarn and anoverlap of a needle loop in the denbigh knit texture or the cord knittexture A′ formed by the middle yarn are toward the same direction inthe same order in one repeat of the knit texture. For example, when theoverlap is formed in an order of the right, left, and right directionsin one repeat of the knit texture of the front yarn, the overlap in onerepeat of the knit texture of the middle yarn is also formed in theorder of the right, left, and right directions. Similarly, it ispreferable that an underlap of a sinker loop in the denbigh knit textureor the cord knit texture A formed by the front yarn and an underlap of asinker loop in the denbigh knit texture or the cord knit texture A′formed by the middle yarn are toward the same direction in the sameorder in one repeat of the knitted texture. By satisfying the conditionsdescribed above, the insertion texture B and the insertion texture B′are easily exposed on the surface of the warp knitted fabric, so thatthe appearance of the woven fabric may be easily obtained. At this time,the needle loop may be any of a closed stitch and an opened stitch.

The height of the insertion texture exposed on the surface of the warpknitted fabric is preferably 0.1 to 2.0 mm, and more preferably 0.2 to1.2 mm. When the height of the insertion texture is 0.1 mm or higher,the strength, especially, the tear strength is hardly damaged. When theheight of the insertion texture is 2.0 mm or lower, the feeling of theknitted fabric hardly becomes rough and hard, and the anti-snaggingproperty is hardly damaged. Here, the height of the insertion texturerefers to the height indicated by the reference numeral “h” in FIGS. 4Aand 4B, and indicates a difference of height between a summit P of thefront yarn 1 (or the middle yarn 2) in the insertion texture and asinker loop summit Q of the cord knit texture formed by the back yarn 3.

Here, the height of the insertion texture exposed on the surface of thewarp knitted fabric is the height of the insertion texture which ismeasured by a method of an Example described hereinbelow.

The ratio of the insertion texture exposed on the surface of the warpknitted fabric is preferably 15 to 60%, and more preferably 25 to 50%.When the ratio of the insertion texture is 15% or more, the appearanceof the woven fabric is easily obtained, and the feeling of the knittedfabric hardly becomes rough and hard. When the ratio of the insertiontexture is 60% or less, the strength is hardly damaged, and theanti-snagging property is hardly damaged.

Here, the ratio of the insertion texture exposed on the surface of thewarp knitted fabric may be calculated as follows.

Insertion texture ratio (%)=sum of the number of courses of theinsertion textures exposed in a 25.4 mm square/(course density×waledensity)×100

In addition, the course density is the number of courses per 25.4 mm,and the wale density is the number of wales per 25.4 mm.

The knit texture formed by the back yarn fed by the back guide bar GB3is the cord knit texture in view of the design and the strength. Thenumber of underlaps in the cord knit texture is preferably 2 to 7needles, and more preferably 3 to 5 needles. When the number ofunderlaps is 2 or more needles, the superimposition of the sinker loopsformed by the back yarn is sufficient, and thus, the obtained knittedfabric hardly becomes see-through, so that the design property is hardlydamaged, and the tear strength is hardly damaged. When the number ofunderlaps is 7 or less needles, the feeling of the knitted fabric hardlybecomes rough and hard, and the stretch of the knitted fabric is largeso that wrinkles hardly occur.

The density of the warp knitted fabric is preferably 20 to 100courses/25.4 mm and 16 to 60 wales/25.4 mm, and more preferably 30 to 70courses/25.4 mm and 20 to 50 wales/25.4 mm. When the density is 20 ormore courses/25.4 mm and 16 or more wales/25.4 mm, the knitted fabrichardly becomes see-through so that the design property is not damaged,and the shape retention property is hardly damaged. Further, since theintervals of the insertion textures are narrow so that the insertionyarn hardly floats and moves, the anti-snagging property is hardlydamaged. When the density is 100 or less courses/25.4 mm and 60 or lesswales/25.4 mm, the feeling of the knitted fabric hardly becomes roughand hard, and the stretch of the knitted fabric is large so thatwrinkles are hardly formed.

The tear strength of the warp knitted fabric is preferably 70 N or more,more preferably 150 N or more, and still more preferably 220 N or more.When the tear strength is 70 N or more, the knitted fabric is hardlytorn during the use thereof. The upper limit value of the tear strengthis not particularly limited, but is preferably 250 N or less. When thetear strength is 250 N or less, the feeling of the knitted fabric hardlybecomes rough and hard, and the knitted fabric is light and easy tohandle. Here, the tear strength is the tear strength which is measuredby a method of an Example described hereinbelow.

The stretch of the warp knitted fabric is preferably 5 N/25.4 mm or morein both the warp direction and the weft direction, and more preferably15 N/25.4 mm or more in the warp direction and 50 N/25.4 mm or more inthe weft direction. Still more preferably, the stretch is 15 N/25.4 mmor more in the warp direction and 50 N/25.4 mm or more in the weftdirection, and the stretch ratio in the warp and weft(lateral/longitudinal) directions is in the range of 0.5 to 2.0. Whenthe stretch is 5 N/25.4 mm or more in both the warp direction and theweft direction, the tension or elasticity of the knitted fabric ishardly reduced so that wrinkles are hardly formed. Here, the stretch isthe stretch which is measured by a method of an Example describedhereinbelow.

The weight of the warp knitted fabric is preferably in the range of 180to 360 g/m², more preferably in the range of 200 to 320 g/m², and stillmore preferably in the range of 240 to 280 g/m². When the weight is 180g/m² or more, the knitted fabric is hardly torn during the use thereof,and the desired design is easily obtained. When the weight is 360 g/m²or less, the feeling of the knitted fabric hardly becomes rough andhard, and the knitted fabric is light and easy to handle.

In addition, in the present embodiment, instead of the knitting usingthe above-described warp knitting machine of three guide bars, theknitting may be performed using a knitting machine of four or more guidebars (i.e., a knitting machine having four or more guide bars). Forexample, in addition to the front guide bar that feeds the front yarn,the middle guide bar that feeds the middle yarn, and the back guide barthat feeds the back yarn, one or multiple base guide bars may beprovided behind the back guide bar, such that the front yarn and themiddle yarn are knitted to be exposed alternately in the warp directionon the sinker loops of the back yarn in the same manner as describedabove. In addition, in the knitting machine of four or more guide bars,multiple middle guide bars may be provided to feed middle yarns, suchthat the front yarn and the multiple middle yarns are knitted to beexposed alternately in the warp direction on the sinker loops of theback yarn.

The obtained warp knitted fabric may be subjected to a well-knownpost-processing of related art (dyeing, heat setting, etc.).

EXAMPLES

Hereinafter, the present embodiment will be described in more detailusing Examples, but the present invention is not limited to theExamples. In addition, the obtained warp knitted fabric was evaluatedaccording to the following methods.

[Design Property]

The obtained warp knitted fabric was evaluated according to thefollowing evaluation criteria.

(Evaluation Criteria)

A: Look like woven fabric

B: Substantially look like woven fabric

C: Substantially look like woven fabric but loops appear

D: Do not look like woven fabric

[Stretch Characteristic]

The obtained warp knitted fabric was evaluated according to thefollowing evaluation criteria.

In order to measure a 5% circular modulus in the warp direction and theweft direction, three circular test pieces each having a size of a 300mm diameter were collected in each of the directions.

Each test piece was put in a low-speed stretch-type tensile tester(Autograph AG-1, manufactured by Shimadzu Corporation) in which thegripping distance was 200 mm. The size of each of the upper and lowergripping jigs was 25.4 mm long×25.4 mm wide on the front side of thejig, and 25.4 mm long×50.8 mm wide on the back side of the jig. At thistime, the initial load was set to 0.98 N.

Each put test piece was pulled at a tensile speed of 200 mm/min to bestretched up to a 20%, so that a load-stretch curve was obtained.

From the obtained load-stretch curve, the load at the time of a 5%stretch (N/25.4 mm) was obtained.

For each direction, an average value of the three test pieces was set asthe value of the 5% circular modulus, and an evaluation was performedaccording to the following evaluation criteria.

(Evaluation Criteria)

A: 15 N/25.4 mm or more in the warp direction, 50 N/25.4 mm or more inthe weft direction, and the warp/weft ratio in the range of 0.5 to 2.0

B: 15 N/25.4 mm or more in the warp direction, 50 N/25.4 mm or more inthe weft direction

C: 5 N/25.4 mm or more and less than 15 N/25.4 mm in the warp direction,and 5 N/25.4 mm or more and less than 50 N/25.4 nm in the weft direction

D: less than 5 N/25.4 mm in any one of the warp-weft directions

[Tear Strength]

Five test pieces were prepared each having a size of a 50 mm width and a250 mm length in which the length direction is set as the warpdirection. An isosceles trapezoid mark having a short side of 100 mm anda long side of 150 mm was attached to each test piece, and a 10 mmincision was formed at the center of the short side of the mark to beperpendicular to the short side.

Each test piece was put in the low-speed stretch-type tensile tester inwhich the gripping distance was 100 mm. At this time, the short side ofthe trapezoid was pulled and the long side thereof was gripped loosely.The test piece was torn at a tensile speed of 200 mm/min to measure thestrength. The tear strength was expressed by an average value N.

The minimum value among the five test pieces was taken as the tearstrength, and the evaluation was performed according to the followingevaluation criteria.

(Evaluation Criteria)

A: 220 N or more

B: 150 N or more and less than 220 N

C: 70 N or more and less than 150 N

D: less than 70 N

[Anti-Snagging Property]

Two test pieces each having a size of a 330 mm width and a 200 mm lengthwere prepared in the respective warp and weft directions. The testpieces were sewn together at positions 30±2.5 mm apart from the endsthereof in the width direction to have a cylindrical shape, while thesurfaces of the pieces face inward.

The sewn cylindrical test pieces were turned inside out such that thesurfaces of the pieces face outward, and put in a drum of a tester. Forthe tester, the ICI mace snag tester (manufactured by Atlas) defined inASTM D3939 was used. The mass of the mace was 160 g. The position of acontact was adjusted using a gauge attached to the tester, the drum wasrevolved 600 times, and then, the test pieces were removed. At thistime, the test pieces in the respective warp and weft directions wereevaluated for each of a case where the drum was revolved forward and acase where the drum was revolved reverse.

The test pieces were compared with standard samples of the ICI in theobservation box to determine the grade. The worst value of the testpieces in the respective warp and weft directions was taken as theanti-snagging property, and the evaluation was performed according tothe following evaluation criteria.

(Evaluation Criteria)

A: Third grade or higher

B: Second grade or higher and lower than third grade

C: Lower than second grade

[Difference of Height of Insertion Texture]

The cross-section of the warp knitted fabric in the width direction wasobserved with a microscope (digital HF microscope VH-8000, manufacturedby Keyence Corporation), and the height difference between the insertionyarn of the insertion texture and the summit of a sinker loop of theback yarn was measured.

Example 1

A tricot knitted fabric was knitted using a 28-gauge tricot knittingmachine (HKS3M: manufactured by Karl Mayer Corporation). Specifically,as illustrated in FIG. 5, a polyester multifilament yarn of 130 dtex/24fwas introduced 1 in 1 out (1 yarn-in 1 yarn-out) as the front yarn tothe front guide bar GB1 to form the denbigh knit texture and theinsertion texture alternately, a polyester multifilament yarn of 130dtex/24f was introduced 1 in 1 out (1 yarn-in 1 yarn-out) as the middleyarn to the middle guide bar GB2 to form the denbigh knit texture andthe insertion texture alternately, and a full set of a polyestermultifilament processed yarn of 167 dtex/48f was introduced as the backyarn to the back guide bar GB3 to form the cord knit texture. At thistime, the overlap direction of the needle loop in the denbigh knittexture formed by the front yarn was the same as the overlap directionof the needle loop in the denbigh knit texture formed by the middleyarn. In addition, the number of courses in which the insertion yarn ofthe inversion texture is continuously exposed on the surface of the warpknitted fabric was 1.

The obtained tricot knitted fabric was subjected to a presetting at 190°C. for one minute in a heat setter, then was dyed and dried at 130° C.,and then was subjected to a final setting at 150° C. for one minute inthe heat setter, so that the tricot knitted fabric with 48 courses/25.4mm and 32 wales/25.4 mm was manufactured as a finished tricot knittedfabric. At this time, the ratio of the insertion texture exposed on thesurface of the warp knitted fabric was 25%, and the height of theinsertion yarn was 0.3 mm. In addition, the design property of theobtained warp knitted fabric was “B”, the stretch characteristic was“A”, the tear strength was “A,” and the anti-snagging property was “B.”

Examples 2 to 8 and Comparative Examples 1 and 2

Warp knitted fabrics of Examples 2 to 8 and Comparative Examples 1 and 2were obtained according to the conditions illustrated in Table 1 andFIGS. 5 to 13 in the same manner as that in Example 1.

In addition, among the Examples, Examples 1 to 6 and 8 are Exampleswhere the lengths of the insertion portions of the front yarn and themiddle yarn (the number of courses of the insertion portions) are thesame, and Example 7 is an Example where the lengths of the insertionportions of the front yarn and the middle yarn are different from eachother.

In addition, among the Examples, Examples 1, 2, and 5 to 8 are Exampleswhere there exists a course in which both the front yarn and the middleyarn are knitted into the base texture (a course which is not aninsertion portion), and Examples 3 and 4 are Examples where there existsno course in which both the front yarn and the middle yarn are knittedinto the base texture. Further, among the Examples, Examples 5 and 8 areExamples where there exist two or more continuous courses in which boththe front yarn and the middle yarn are knitted into the base texture,and more specifically, Examples where there exist three continuouscourses in which both the front yarn and the middle yarn are knittedinto the base texture.

In addition, among the Examples, Examples 1 to 4, 6, and 7 are Exampleswhere the insertion portions of the front yarn and the middle yarn arearranged alternately with no intervals in the course direction, in viewof the appearance of the warp knitted fabric, and Examples 5 and 8 areExamples where the insertion portions of the front yarn and the middleyarn are arranged alternately at intervals in the course direction, inview of the appearance of the warp knitted fabric.

Table 1 represents the evaluation results.

TABLE 1 Example 1 Example 2 Example 3 Example 4 Example 5 KnittingMachine HKS3M HKS3M HKS3M HKS3M HKS3M Gauge 28  28  28  28  28  KnitFront Yarn PET PET PET PET PET Texture Body Multifilament MultifilamentMultifilament Multifilament Multifilament Yarn Yarn Yarn Yarn YarnFineness 130/24 130/24 130/24 130/24 130/24 Yarn Arrangement 1in 1out1in 3out 1in 1out 1in 1out 1in 1out Knit Texture 1-0/1-1/1-0/1-21-0/1-1/1-0/2-3 1-1/1-1/1-1/ 1-1/1-1/1-1/1-1/ 1-0/1-2/1-0/1-1/1-0/1-2/1-0 1-0/1-2/1-0/1-1 1-0/1-2/1-0/1-2 Knit Texture Denbigh CordDenbigh Denbigh Denbigh (2 Needles) Overlap Direction RightRightLeft RRLRLR RLR RLR RLRL (RRL) Number of Courses 3 3 3 3 7 (Base Texture) Numberof Courses 1 1 3 5 1 (Insertion Texture) Middle Yarn PET PET PET PET PETBody Multifilament Multifilament Multifilament MultifilamentMultifilament Yarn Yarn Yarn Yarn Yarn Fineness 130/24 130/24 130/24130/24 130/24 Yarn Arrangement 1out 1in

out 1in 1out 1in 1out 1in 1out 1in Knit Texture 1-0/1-2/1-0/

-1 1-0/2-3/1-0/

-

1-0/1-2/1-0/1-1/ 1-0/1-2/1-0/1-1/ 1-0/1-2/1-0/1-2/ 1-1/1-11-1/1-1/1-1/1-1 1-0/1-2/1-0/1-1 Knit Texture Denbigh Cord DenbighDenbigh Denbigh (2 Needles) Overlap Direction RLR RLR RLR RLR RLRL

R Number of Courses 3 3 3 3 7 (Base Texture) Number Of Courses 1 1 3 5 1(Insertion Texture) Back Yarn PET PET PET PET PET Body MultifilamentMultifilament Multifilament Multifilament Multifilament Processed YarnProcessed Yarn Processed Yarn Processed Yarn Processed Yarn Fineness167/48 167/48 167/48 167/48 167/48 Yarn Arrangement Full Set Full SetFull Set Full Set Full Set Knit Texture Cord Cord Cord Cord Cord (3Needles) (

 Needles) (3 Needles) (3 Needles) (3 Needles) 1-0/5-4 1-0/8-7 1-0/3-41-0/3-4 1-0/3-4 Warp Weight (g/m2) 250  3

0 270  2

0 270  Knitted Density Courses 48  34  53  60  3

Fabric Wales 32  32  34  34  32  Insertion Height (mm)   0.3 0.

  0.7 1   0.3 Texture Exposure 25% 25% 50%

3% 13% Ratio (%) Evaluation Design Properly A B B B B StitchCharacteristic A C B B C Tear Strength A A B B A Anti-Snagging ProperlyA A B B A Comparative Comparative Example 6 Example 7 Example 8 Example1 Example 2 Knitting Machine HKS3M HKS3M HKS3M HKS3M HKS3M Gauge 28  28 28  28  28  Knit Front Yarn PET PET PET PET PET Texture BodyMultifilament Multifilament Multifilament Multifilament MultifilamentYarn Yarn Yarn Yarn Yarn Fineness 130/24 130/24 130/24 130/24 130/24Yarn Arrangement 2in 2out 1in 1out 1in 1out 1in 1out 1in 1out KnitTexture 1-0/1-1/1-0/1-2 1-0/1-2/1-0/1-2/ 1-0/1-1/1-1/1-1/1-1/1-1/1-0/0-1 1-0/1-1/1-0/1-2 1-0/1-1 1-0/1-2/1-0/1-

/ 1-0/1-2/1-

/1-2 Knit Texture Denbigh Denbigh Denbigh Chain Denbigh OverlapDirection RRL RLRLR R

RL RRL Number of Courses 3

9 2

(Base Texture) Number of Courses 1 1 3 2 1 (Insertion Texture) MiddleYarn PET PET PET PET PET Body Multifilament Multifilament MultifilamentMultifilament Multifilament Yarn Yarn Yarn Yarn Yarn Fineness 130/24130/24 130/24 130/24 130/24 Yarn Arrangement 2out 2in 1out 1in 1out 1in1out 1in 1out 1in Knit Texture 1-0/1-2/1-0/1-1 1-0/1-1/1-1/1-1/ 1-0/

-2/1-0/1-

/ 1-0/0-1/1-1/1-1 1-0/1-2/1-0/1-1 1-0/1-2 1-0/1-2/1-0/1-1/ 1-1/1-

/1-

/1-2 Knit Texture Denbigh Denbigh Denbigh Chain Denbigh OverlapDirection RLR R RL RLR

R

RL RL RLR Number of Courses 3 3 9 2 3 (Base Texture) Number Of Courses 13 3 2 1 (Insertion Texture) Back Yarn PET PET PET PET PET BodyMultifilament Multifilament Multifilament Multifilament MultifilamentProcessed Yarn Processed Yarn Processed Yarn Processed Yarn ProcessedYarn Fineness 167/48 167/48 167/48 167/48 167/48 Yarn Arrangement FullSet Full Set Full Set Full Set Full Set Knit Texture Cord Cord Cord CordDenbigh (3 Needles) (3 Needles) (3 Needles) (3 Needles) 1-0/1-2 1-0/3-41-0/3-4 1-0/3-4 1-0/3-4 Warp Weight (g/m2) 250  280  280  240  180 Knitted Density Courses 48  48  48  38 

0 Fabric Wales 32  32  32  34  33  Insertion Height (mm)   0.4   0.6  0.8   0.1   0.2 Texture Exposure 25% 33% 25%

0% 25% Ratio (%) Evaluation Design Properly B B B B D StitchCharacteristic A B B B C Tear Strength A B A C C Anti-Snagging ProperlyA B B B A

indicates data missing or illegible when filed

DESCRIPTION OF REFERENCE NUMERALS AND SIGNS

1: front yarn, 2: middle yarn, 3: back yarn, 20, 21: a portion of aninsertion texture

1. A warp knitted fabric formed of yarns fed from at least three guidebars including front, middle, and back guide bars, wherein a back yarnfed from the back guide bar forms a cord knit texture, a front yarn fedfrom the front guide bar and a middle yarn fed from the middle guide barare arranged alternately in a weft direction, each of the front yarn andthe middle yarn forms a stitch formation texture and an insertiontexture alternately in a warp direction, the stitch formation texture ofeach of the front yarn and the middle yarn is a denbigh knit texture ora cord knit texture, and the insertion texture formed by the front yarnand the insertion texture formed by the middle yarn are arrangedalternately at least in the warp direction so that the front yarn andthe middle yarn are exposed alternately at least in the warp directionon sinker loops of the back yarn.
 2. The warp knitted fabric accordingto claim 1, wherein each of the front yarn and the middle yarn forms thedenbigh knit texture and the insertion texture alternately in the warpdirection.
 3. The warp knitted fabric according to claim 1, wherein aratio of the insertion texture exposed on a surface of the warp knittedfabric is 15 to 60%.
 4. The warp knitted fabric according to claim 1,wherein the stitch formation textures and the insertion textures formedby the front yarn and the middle yarn are continuous in 1 to 5 courses.5. A method of manufacturing a warp knitted fabric, comprising: using awarp knitting machine provided with at least three guide bars includingfront, middle, and back guide bars; knitting a cord knit texture byfeeding a back yarn from the back guide bar; knitting a stitch formationtexture and an insertion texture alternately in a warp direction byfeeding a front yarn from the front guide bar; knitting a stitchformation texture and an insertion texture alternately in the warpdirection by feeding a middle yarn from the middle guide bar; knitting adenbigh knit texture or a cord knit texture as the stitch formationtexture of each of the front yarn and the middle yarn; and arranging theinsertion texture formed by the front yarn and the insertion textureformed by the middle yarn alternately at least in the warp direction soas to expose the front yarn and the middle yarn alternately at least inthe warp direction on sinker loops of the back yarn.
 6. The method ofmanufacturing a warp knitted fabric according to claim 5, comprising:knitting the denbigh knit texture and the insertion texture alternatelyin the warp direction by feeding the front yarn from the front guidebar; knitting the denbigh knit texture and the insertion texturealternately in the warp direction by feeding the middle yarn from themiddle guide bar; and arranging the insertion texture formed by thefront yarn and the insertion texture formed by the middle yarnalternately at least in the warp direction.
 7. The method ofmanufacturing a warp knitted fabric according to claim 5, wherein aratio of the insertion texture to be exposed on a surface of the warpknitted fabric is 15 to 60%.
 8. The method of manufacturing a warpknitted fabric according to claim 5, comprising: knitting the stitchformation textures and the insertion textures formed by the front yarnand the middle yarn to be continuous in 1 to 5 courses.